Lincoln Electric SVM138-A User Manual

SVM138-A

June, 1998

Safety Depends on You

Lincoln arc welding equipment
is designed and built with safety
in mind. However, your overall
safety can be increased by
proper installation. . . and
thoughtful operation on your
part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

SERVICE MANUAL

For use with machines having Code Numbers: 9100 and Above

LN-9 GMA Wire Feeder

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

World's Leader in Welding and Cutting Products Premier Manufacturer of Industrial Motors

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FOR ENGINE
powered equipment.

1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.

____________________________________________________

1.b.Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.

____________________________________________________

1.c. Do not add the fuel near an open flame weld­ing arc or when the engine is running. Stop
the engine and allow it to cool before refuel­ing to prevent spilled fuel from vaporizing on
contact with hot engine parts and igniting. Do
not spill fuel when filling tank. If fuel is spilled,
wipe it up and do not start engine until fumes
have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in posi­tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safety

guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

___________________________________________________

1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.

i

SAFETY

i

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society , P.O. Box 351040,
Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the
Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.

2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.

2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as

possible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel engine exhaust and some of its constituents
are known to the State of California to cause can­cer, birth defects, and other reproductive harm.

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Diesel Engines

The Above For Gasoline Engines

LN-9 GMA Wire Feeder

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SAFETY

ii ii

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK can kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.

3.f.

Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASES
can be dangerous.

5.a.Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.

5.b.

Do not weld in locations near chlorinated hydrocarbon

vapors
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors

to
form phosgene, a highly toxic gas, and other irritating
products.

5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.e. Also see item 1.b.

LN-9 GMA Wire Feeder

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SAFETY

iii iii

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.

8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

•Away from areas where they may be struck or subjected to

physical damage.

•A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.

7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

WELDING SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

the welding sparks from starting a fire.

Remember that welding sparks and hot
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.

6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact can
cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even

though

they have
been “cleaned”. For information, purchase “Recommended
Safe Practices for the

Preparation

for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.

6.f.

Sparks and spatter are thrown from the welding arc. Wear oil
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits.
This can create fire hazards or overheat lifting chains or
cables until they fail.

6.h. Also see item 1.c.

LN-9 GMA Wire Feeder

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SAFETY

iv iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter tou­jours tout contact entre les parties sous tension et la
peau nue ou les vétements mouillés. Porter des gants
secs et sans trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement
dans les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d. Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous ten-

sion des porte-électrodes connectés à deux machines à
souder parce que la tension entre les deux pinces peut
être le total de la tension à vide des deux machines.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enroule le câble-électrode autour de n’importe quelle partie du
corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnementde
l’arc.

c. Protéger l’autre personnel travaillant à proximité au

soudage à l’aide d’écrans appropriés et non-inflamma­bles.

4. Des gouttes de laiter en fusion sont émises de l’arc de
soudage. Se protéger avec es vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir ttout risque d’incendie dû étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé
de la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de la faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le
risque de voir passer le courant de soudage par les chaines
de levage, câbles de grue, ou atres circuits. Cela peut
provoquer des risques d’incendie ou d’echauffement des
chaines et des câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumées toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opéerations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du solvant pour produire du phosgéne (gas forte­ment roxique) ou autres produits irritants.

PRÉCAUTIONS DE SÛRETÉ POUR LES
MACHINES À SOUDER À TRANSFOR­MATEUR ET À REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dis­positif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.

2. Autant que possible, l’installation et l’entretien du poste
seront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispostifis de sûreté à leur
place.

LN-9 GMA Wire Feeder

MASTER TABLE OF CONTENTS

v v

Page

Safety.................................................................................................................................................i-iv

Installation.............................................................................................................................Section A

Technical Specifications..............................................................................................................A-2

Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3

Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3

Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4

Machine Grounding ...................................................................................................................A-12

Work Cable Connection............................................................................................................A-12

Connecting the Gun Cable to the Wire Feeder ........................................................................A-13

Hooking Up GMA Shielding Gas...............................................................................................A-14

Operation...............................................................................................................................Section B

Operating Instructions.................................................................................................................B-2

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment.................................................................................B-3

Controls and Settings..................................................................................................................B-5

Drive Roll Installation ................................................................................................................B-10

Wire Loading.............................................................................................................................B-14

Idle Roll Pressure Setting .........................................................................................................B-18

Making a Test Weld and Adjusting Response and Starting......................................................B-19

Procedure at End of Coil...........................................................................................................B-21

Security of Weld Procedure Settings........................................................................................B-21

Accessories ..........................................................................................................................Section C

Auxiliary Equipment Contacts.....................................................................................................C-2

Optional Equipment and Accessories .........................................................................................C-2

Maintenance..........................................................................................................................Section D

Routine Maintenance..................................................................................................................D-2

Periodic Maintenance .................................................................................................................D-2

Gun and Cable Maintenance......................................................................................................D-3

Theory of Operation .............................................................................................................Section E

LN-9 GMA Wire Feeder

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MASTER TABLE OF CONTENTS

(cont’d)

vi vi

Troubleshooting....................................................................................................................Section F

How to Use Troubleshooting Guide............................................................................................F-2

PC Board Troubleshooting Procedures.......................................................................................F-3

Troubleshooting Guide................................................................................................................F-4

Electrical Diagrams..............................................................................................................Section G

Parts...................................................................................................................................P289 Series

LN-9 GMA Wire Feeder

RETURN TO MAIN INDEX

NOTES

vii vii

LN-9 GMA Wire Feeder

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TABLE OF CONTENTS

- INSTALLATION SECTION -

Section A-1

Section A-1

Installation

Technical Specifications..............................................................................................................A-2

Installing the LN-9GMA 2-Roll and 4-Roll Models ......................................................................A-3

Attaching the Wire Reel stand ..............................................................................................A-3

Mounting the Unit .................................................................................................................A-3

Installing the LN-9F GMA 2-Roll and 4-Roll Models...................................................................A-3

Mounting the Wire Feed Unit................................................................................................A-3

Mounting the Control Box.....................................................................................................A-3

Connecting the Wire Feed Unit to the Control Box..............................................................A-3

Routing the Electrode...........................................................................................................A-4

Electrical Connections - LN-9 GMA and LN-9F GMA.................................................................A-4

Power Input Cable Assembly ..............................................................................................A-4

Connecting the Power Input Cable Assembly to the LN-9 GMAWire Feed Unit ................A-4

Connecting the Power Input Cable Assembly to the LN-9F GMAWire Feed Unit .............A-5

Connecting the Power Input Cable Assembly to Power Sources........................................A-5

Machine Grounding ...................................................................................................................A-12

Work Cable Connection............................................................................................................A-12

Direct Work Lead Connection.............................................................................................A-12

Connecting the Gun Cable to the Wire Feeder ........................................................................A-13

For GMA Gun Cables .........................................................................................................A-13

Hooking Up GMA Shielding Gas...............................................................................................A-14

LN-9 GMA Wire Feeder

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INSTALLATION

A-2 A-2

LN-9 GMA Wire Feeder

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TECHNICAL SPECIFICATIONS

INPUT POWER

Supplied by power source: 115 VAC, 50/60 Hz., 350 VA

WIRE FEED SPEED

80 to 980 inches per minute (2.03 to 24.9 meters per minute)

VOLTAGE CONTROL RANGE

12.0 TO 60.0 VDC

TEMPERATURE RANGE

OPERATION: - 20oC to +40oC (- 4oF to +104oF) Recommended

- 40oC to +40oC (- 40oF to +104oF) Maximum Rated

STORAGE: - 40oC to +85oC (- 40oF to +185oF)

WIRE DIAMETERS

0.023 through 1/16 Solid Electrode

0.045 through 5/64 Cored Electrode

PHYSICAL DIMENSIONS

LENGTH WIDTH HEIGHT TOTAL WEIGHT LESS

ELECTRODE

LN-9 GMA (2 ROLL) 12.15 in. 11.56 in. 12.19 in. 29.3 lbs

(308.4 mm) (293.4 mm) (309.4 mm) (13.3 kg)

LN-9 GMA (4 ROLL) 12.15 in. 11.56 in. 12.19 in. 27.5 lbs

(308.4 mm) (293.4 mm) (309.4 mm) (12.4 kg)

LN-9F GMA Control Box 10.4 in. 6.17 in. 11.26 in. 16.3 lbs

(264 mm) (156.6 mm) (293.4 mm) (7.4 kg)

LN-9F GMA Wire Drive (2 ROLL) 8.06 in. 7.5 in. 12.78 in. 15.6 lbs

(204.6 mm) (190.4 mm) (324.4 mm) (7.1 kg)

LN-9F GMA Wire Drive (4 ROLL) 8.06 in. 7.5 in. 12.78 in. 20.5 lbs

(204.6 mm) (190.4 mm) (324.4 mm) (9.2 kg)

INSTALLING THE LN-9 GMA
2-ROLL AND 4-ROLL MODELS

ATTACHING THE WIRE REEL STAND

Both the 2-Roll and 4-Roll LN-9 GMAare shipped with­out the wire reel stand attached. The screws and wash­ers for mounting the wire reel stand are included with
the LN-9 GMA (fastened in their respective mounting
holes). To attach the stand:

1. Remove the three 3/8" hex screws from the back of
the wire feed unit.

2. Place the wire reel stand mounting bracket in posi­tion against the back of the wire feed unit.

3. Replace and tighten the screws. The long screw
and plain washer go into the top hole. For 4-Roll
feeders, one plain washer is used for mounting 60#
wire stands and 2 plain washers for mounting 30#
stands.

MOUNTING THE UNIT

LN-9 GMAwire feeders can be mounted directly on top
of their power source as long as it is secure and level.
When portability is required, the LN-9 GMA can be
mounted on a K163 undercarriage See the

Accessories

section for details.

AK1557-1 swivel platform is available for mounting the
LN-9 GMA to the power source. See the

Accessories

section for details.

INSTALLING THE LN-9F GMA
2-ROLL AND 4-ROLL MODELS

MOUNTING THE WIRE FEED UNIT

Mount the wire feed unit by means of the insulated
mounting bracket attached to the bottom of the gear­box. Refer to the LN-9F GMA Dimension Print in the

Diagrams

section of this manual for the size and loca­tion of the mounting holes. The gearbox assembly is
electrically "hot" when the gun trigger is pressed.
Therefore, make certain the gearbox does not come in
contact with the structure on which the unit is mounted.
The wire feed unit should be mounted so that the drive
rolls are in a vertical plane so dirt will not collect in the
drive roll area. Position the mechanism so it will point
down at about a 45oangle so the wire feed gun cable
will not be bent sharply as it comes from the unit.

MOUNTING THE CONTROL BOX

The same control box is used for both the 2-Roll and 4­Roll wire feed unit. It contains two keyhole slots and
one slot for mounting. Refer to the LN-9F GMA
Dimension Print in the

Diagrams

section of this manu­al for the size and location of these slots. Mount the
box at some convenient location close to the wire feed
unit. This will enable the 16-foot control cable assem­bly supplied with both the LN-9F GMA2-Roll and 4-Roll
to reach between the control box and the wire feed
unit.

1. Drill the required holes in the mounting surface.

Partially install 1/4-20 screws.

2. Open the control box door by removing the two door

screws.

3. Mount the box.

4. Tighten the screws.

5. Close the control box door and replace the door

screws.

CONNECTING THE WIRE FEED UNIT TO
THE CONTROL BOX

Both the LN-9F GMA 2-Roll and 4-Roll include the
same 16 ft. control and electrode cable assembly.
Connect the wire feed unit to the control box as follows:

1. Make certain the cables are protected from any

sharp corners that may damage their jackets.
Mount the cable assembly along the boom so the
end with the female amphenol connector pins is at
the wire feed unit.

2. Connect the cable connector to the receptacle on

the back of the wire feed unit connection box.

3. At the same end, connect the electrode lead to the

connection stud of the copper strap along the side
of the wire feed unit.

4. At the control box end, connect the amphenol con-

nector of the control cable to the mating MS-type
receptacle on the bottom of the control box. (See

Figure A.3,

later in this section, for the location of

this connection.)

INSTALLATION

A-3 A-3

LN-9 GMA Wire Feeder

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ROUTING THE ELECTRODE

The electrode supply may be either from reels, Readi­Reels, spools, or bulk packaged drums or reels.
Observe the following precautions:

• The electrode must be routed to the wire feed unit so
that the bends in the wire are at a minimum. The
force required to pull the wire from the reel into the
wire feed unit must be kept at a minimum.

• The electrode is "hot" when the gun trigger is
pressed and must be insulated from the boom and
structure.

• If more than one wire feed unit share the same
boom, their wire and reels must be insulated from
each other and insulated from their mounting struc­ture.

See the

Accessories

section for information about

mounting a K299 wire reel assembly.

ELECTRICAL CONNECTIONS ­LN-9 GMA AND LN-9F GMA

POWER INPUT CABLE ASSEMBLY

A special cable assembly is required to connect all LN­9 GMA models to the power source. The assembly
includes control cable and electrode cable. Various
sizes are available, based on length and maximum
welding current. The following power source cable
assemblies are available:

K196 for Terminal Strip control connection and output
terminal.

K595 for 14-Pin receptacle and output terminal.
K596 for 14-Pin receptacle and Twist-Mate" connec-

tion.
NOTE: Use of an LN-9 GMA with a Pulse Power 500,

Invertec V300 or a DC650 PRO requires a K442-1
Pulse Power Filter Kit.

CONNECTING THE POWER INPUT
CABLE ASSEMBLY TO THE LN-9 GMA

WIRE FEED UNIT

The K196, K595, or K596 cable assembly consists of
an electrode cable and multiconductor control cable.
The control cable has a polarized plug on the wire
feeder end. To install:

1. See Figure A.1. Connect the polarized plug of the
control cable to the mating connector on the back
of the wire feeder.

2. See

Figure A.2.

Remove the screws holding the
cable strain relief clamp located near the rear of
the wire reel stand base. Put the control cable and
the electrode cable under the clamp and install the
screws.

For cables with more than one electrode cable,
leave the junction between the two or more cables
and the single 4/0 stub behind the clamp so that
only the single electrode lead is under the clamp.

3. See Figure A.1. Pass the single electrode cable
through the hole provided in the back corner of the
wire section and fasten it to the conductor block of
the copper strap along the side of the wire drive
unit.

INSTALLATION

A-4 A-4

LN-9 GMA Wire Feeder

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FIGURE A.1 – INPUT CONTROL CABLE AND

ELECTRODE CABLE CONNECTIONS

INSTALLATION

A-5 A-5

LN-9 GMA Wire Feeder

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FIGURE A.2 – STRAIN RELIEF CLAMP

CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO THE LN-9F CONTROL

BOX

1. See Figure A.3. Connect the polarized plug of the
K196, K595, or K596 control cable to the mating
MS-type connector on the bottom of the LN-9F
GMA control box.

2. Bolt the electrode lead from the power source to the
electrode lead to the wire feed unit using the nut
and bolt supplied. Insulate the connection with elec­trical tape.

CONNECTING THE POWER INPUT CABLE
ASSEMBLY TO POWER SOURCES

Turn input supply power to the power source OFF
before connecting the LN-9 GMA or LN-9F GMA wire
feeder.

Connect to an appropriate Lincoln power source as fol­lows:

1. If using a multipurpose source (such as the DC­250, DC-400 and DC-600), be sure it is properly
set for the welding process being used. See the
topic

"Making a Test Weld,"

in the

Operation

sec-

tion of this manual.

For terminal strip connections using the K196 power
input cable, connect the input cable to the power
source exactly as specified on the appropriate LN-9
GMA model connection diagram:

Figure A.4 for DC-250, DC-400 and CV-400, CV-500 l
Figure A.5 for DC-600
Figure A.6 for DC-1000
Figure A.7 for Pulse Power 500
Figure A.8 for V300

FIGURE A.3 – LN-9F GMA CONTROL BOX

BOTTOM VIEW

WARNING

Figure A.8 is a connection diagram for connecting the
LN-9 GMA to V300 power sources. The connection is
made with a K596 cable assembly, which has an
amphenol connection rather than a terminal strip con­nection at the power source.

Depending on the power source and process you are
using, the jumpers on the LN-9 GMA voltage board
may have to be changed. As shipped, the LN-9 GMAis
connected for use with the DC-250 DC-400, CV-400,
CV-500-I and DC-600. For other power sources, refer
to the appropriate connection diagram.

NOTE: If you are using the Pulse Power 500, DC650
Pro, or V300 power source, the K442-1 Pulse Power
Filter Kit must be installed in the LN-9 GMA. See the
instructions included with the kit. If you are using the
Invertec V300, the K608-1 Adapter must also be
installed according to the connection diagram and
instructions provided in the Invertec Manual.

INSTALLATION

A-6 A-6

LN-9 GMA Wire Feeder

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INSTALLATION

A-7 A-7

LN-9 GMA Wire Feeder

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FIGURE A.4 – CONNECTION OF LN-9 GMA TO DC-250, DC-400, and CV/CVI POWER SOURCES

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.

* Does not apply to DC-400 below code 9200 with polarity switch.
N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage

sensing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the weld­ing work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (If the
length of work lead circuit is short, and connections can be expected to be reliable, then control cable lead #21 does not need to
be extended and can be directly connected to terminal #21 on the terminal strip. Note that this is not the preferred connection

because it adds error to the wire feeder voltmeter reading.)
N.C. Tape up bolted connection if lead #21 is extended.
N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source

grounding terminal (marked and located near the power source input power connections) must be properly connected to elec-

trical ground per the power source operating manual.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.
Blue jumper on voltage board (later units only), or on start board (earlier units), to pin “B”.

*N.G. If lead #21 is to be connected to the terminal strip, connect to the #21 terminal that matches work polarity. This connection must

be changed whenever the electrode polarity is changed.

WARNING

• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connect­ing the wire feeder

• Only qualified persons should install,
use or service this machine.

ELECTRIC SHOCK

can kill.

TO LN-9 GMA INPUT CABLE PLUG

TO LN-9 GMA INPUT CABLE PLUG

INSTALLATION

A-8 A-8

LN-9 GMA Wire Feeder

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FIGURE A.5 – CONNECTION OF LN-9 GMA TO DC-600 POWER SOURCES

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and position the switch on power source to proper polarity.

For optimum performance with the LN-9 GMA, DC-600’s with codes 8288 and above are preferred.
N.B. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.C. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sensing

work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding work
lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead. (This extended

#21 lead connection replaces the need to employ the remote work lead accessory on LN-9’s which have a direct work lead jack.)
N.D. Tape up bolted connection.
N.E. Connect the LN-9 GMA control cable ground lead to the frame terminal marked near the power source terminal strip. The

power source must be properly grounded.
N.G. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (Earlier units) to pin “B”.

N.H. For DC-600 Codes below 8200 connect a jumper from “N” to “P” on LN-9 GMA only. There is no NPS terminal strip on codes

above 8200.

ELECTRIC SHOCK

can kill.

• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connect­ing the wire feeder

• Only qualified persons should install,
use or service this machine.

WARNING

INSTALLATION

A-9 A-9

LN-9 GMA Wire Feeder

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FIGURE A.6 – CONNECTION OF LN-9 GMA TO DC-1000 POWER SOURCES

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source, position the positive - negative switch on power source to correspond to the polarity of the electrode cable connection.

N.A. Welding cables must be proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using #14 or larger insulated wire physically suitable for the installation. an S16586 remote voltage sensing work

lead is available for this purpose. Connect it directly to the work piece keeping it separate from the welding work cable connection
to work piece. For convenience, this extended #21 lead should be taped along the welding work cable. (This extended #21 lead

connection replaces the need to employ the remote work lead accessory on any LN-9 GMA which has a direct work lead jack).
N.C. Tape up bolted connection.
N.D. Connect the LN-9 GMA control cable ground lead to the frame terminal marked near the power source terminal strip. The

power source must be properly grounded.
N.E. If using an older automatic control cable with leads #75, #76, #77; connect lead #75 to #75 on terminal strip, connect lead #76 to

#74 on terminal strip, connect lead #77 to #73 on terminal strip.
N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.
Blue jumper on voltage board (Later units only) or on start board (earlier units) to pin “B”.

N.G. Set the DC-1000 controls as follows:

Set the control switch to “output control remote”. For submerged arc processes, set the mode switch to “C.V. submerged arc”.
For open arc processes, set the mode switch to “C.V. Innershield”.

N.H. Alternative 500 amp positive terminal connection provided on DC-1000 models above code 9500 only.

WARNING

• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connect­ing the wire feeder

• Only qualified persons should install,
use or service this machine.

ELECTRIC SHOCK

can kill.

TO LN-9 GMA INPUT CABLE PLUG

INSTALLATION

A-10 A-10

LN-9 GMA Wire Feeder

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FIGURE A.7 – CONNECTION OF LN-9 GMA TO PULSE POWER 500 POWER SOURCES

Above diagram shows electrode connected positive. To change polarity, turn power off, reverse the electrode and work leads at the
power source and properly set the feeder polarity switch.

N.A. Welding cables must be of proper capacity for the current and duty cycle of immediate and future applications.
N.B. Extend lead #21 using 14 AWG or larger insulated wire physically suitable for the installation. An S16586-[ ] remote voltage sens-

ing work lead is available for this purpose. Connect it directly to the work piece keeping it electrically separate from the welding

work lead circuit and connection. For convenience, this extended #21 lead should be taped to the welding work lead.
N.C. Tape up bolted connection.
N.D. Connect the control cable ground lead to the frame terminal marked near the power source terminal strip. The power source

grounding terminal (marked and located near the power source input power connections) must be properly connected to elec­trical ground per the power source Operating Manual.

N.E. Connect control leads t terminal strip as follows:

LN-9: A to 75 B to 77 C to 78

N.F. The LN-9 GMA voltage control jumpers must be connected as follows:

White jumper on voltage board to pin “S”.
Blue jumper on voltage board is not connected to any pin. (Secure loose jumper clear of any possible interference.)

NOTE: For proper pulse welding operating with LN-9:

1. The LN-9 GMA must have an L6084-3 (or higher superseding part number) voltage board installed. (Standard above code

9100.)

2. The Pulse Power Filter board must be installed and connected in the LN-9 per instructions provided with the kit.

3. The pulse current sensor assembly (with looped copper energizer) must be installed. (Standard above code 9100.) Feeder
conversion kits are available for all LN-9 GMA model codes (below 9100 and above 9100).

WARNING

• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connect­ing the wire feeder

• Only qualified persons should install,
use or service this machine.

ELECTRIC SHOCK

can kill.

TO LN-9 GMA INPUT CABLE PLUG

INSTALLATION

A-11 A-11

LN-9 GMA Wire Feeder

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FIGURE A.8 – CONNECTION OF LN-9 GMA TO V300 POWER SOURCES

N.A. Welding cable must be sized for current and duty cycle of application.
N.B. Diagram shows electrode positive. To change polarity, turn power “OFF”, reverse electrode and work cable at power source. Set

meter polarity switch on rear of invertec to coincide with polarity used. Set LN-9 GMA polarity switch also.

N.C. Install K608-1 adapter in line with P10 to LN-9 GMA voltage board and secure to adjacent harness with wire tie provided. Turn

“start” trimmer on voltage board per instructions in V300 manual.

N.D. For GMAW welding, install Pulse Power Filter Kit K442-1 in LN-9 GMA.

WARNING

• Turn off input power to the welding
power source using the disconnect
switch at the fuse box before connect­ing the wire feeder

• Only qualified persons should install,
use or service this machine.

ELECTRIC SHOCK

can kill.

ELECTRODE CABLE
TO LN-9 GMA

TO WORK

INVERTEC
POWER SOURCE
WITH 110/115V AUX.

14 PIN
AMPHENOL

CONNECTION

LN-9 GMA WITH
K608-1 AND
K442-1 KITS

K596 REMOTE
CONTROL CABLE
ASSEMBLY

P10,J10'

2
3
4
5
6
7

10

K608-1

DETAIL

530A

521
500
500
524

C

3.9K ohm

P10',J10

2
3
4
5
6

11

11
12

B

533

7

12

INSTALLATION

A-12 A-12

LN-9 GMA Wire Feeder

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MACHINE GROUNDING

LN-9 GMA wire feeders are grounded to the power
source through the input cable. The power source
grounding cable must be properly connected to electri­cal ground. See your power source operating manual
for details.

WORK CABLE CONNECTION

Connect a work lead of sufficient size and length
between the proper output terminal on the power
source and the work. See Table A-1. Be sure the con­nection to the work makes tight metal-to-metal electri­cal contact. Poor work lead connections can activate
the grounding lead protector and/or result in poor weld­ing performance.

TABLE A.1 – WORK CABLE SIZES

Current

Copper Work Cable Size, AWG

60% Duty Cycle

Up to 50' length 50'-100' Iength
300 Amps 0 00
400 Amps 00 000
500 Amps 00 000
600 Amps 000 0000

DIRECT WORK LEAD CONNECTION

Lincoln specified procedures give voltage readings
taken between the work and the gun cable brass con­nection block of the LN-9 GMA. To match these voltage
readings, the connection diagrams show the #21 lead
being extended and connected directly to the work
instead of #21 on the power source terminal strip (or
Dual Process Kit terminal strip). This extended lead
must be connected directly to the work. When using a
Dual Process Kit, you must extend the lead individual­ly for each LN-9 GMA.

As an alternative, LN-9 GMA models are provided with
a quick-connect terminal splice connection in the #21
lead between the input Amphenol connector of the LN9
GMA and its polarity switch. See the LN-9 GMA wiring
diagram. This in-line connection consists of a red insu­lated male and female .250 x .032 terminal pair locat­ed in the lead harness. It runs along the right side of
the wire feed motor inside the control section of the LN­9 GMAmodels and in the lead harness at the lower left
corner of the control box (near the input Amphenol) of
the LN-9F models. You may also open this #21 lead
and connect your own direct work lead equipped with a
.250 x .032 female quick-connect terminal to the male
side of the splice. This direct work lead connection
must be tape insulated, strain-relieved, and routed out­side the LN-9 GMA control box to be connected direct­ly to the work.

With either direct work lead connection method, the
LN-9 GMA regulates the power source to hold the arc
voltage constant, even with voltage drops in the elec­trode lead, work lead, or work lead connection. If the
direct work lead becomes disconnected from the work,
the LN-9 GMA wire feeder will stop welding shortly
after the arc is struck. See the topic "

Circuit

Protection and Automatic Shutdown"

in the

Operation

section of this manual.

INSTALLATION

A-13 A-13

LN-9 GMA Wire Feeder

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CONNECTING THE GUN CABLE TO
THE WIRE FEEDER

A variety of gun and cable assemblies are available for
the LN-9 GMA models. See the

Accessories

section

of this manual.
Lay the cable out straight. Insert the connector on the

welding conductor cable into the brass conductor block
on the front of the wire drive unit. See Figure A.9. Make
sure the connector is fully seated and tighten the plas­tic thumbscrew. Keep this connection clean and bright.
Connect the control cable polarized Amphenol plug into
the mating 5-cavity receptacle on the front panel of the
wire drive section.

FOR GMA GUN CABLES:

Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9 GMA
wire drive section. Connect the 3/16" I.D. gas hose
from the gun cable to the barbed fitting.

When you remove the gun, you can easily detach this
fitting by loosening the union nut.

FIGURE A.9 – GUN CABLE CONNECTIONS

Thumb­screw

HOOKING UP GMA SHIELDING
GAS

CYLINDER may explode if
damaged.

• Gas under pressure is explosive.

•· Always keep gas cylinders in an
upright position and always keep
them chained to the undercarriage
or a stationary support.

See American National Standard Z-49.1, "Safety in
Welding and Cutting," published by the American
Welding Society.

The user must provide a cylinder of shielding gas, a
pressure regulator, a flow control valve and a hose
from the flow valve to the gas inlet fitting of the LN-9
GMA. See Figure A.10 and install as follows:

1. Connect the supply hose from the gas cylinder flow
valve outlet to the 5/8-18 female inert gas fitting on
the back panel of the LN-9 GMAwire drive section.

2. Install the barbed fitting and union nut to the 5/8-18
female inert gas fitting on the front of the LN-9
GMA. Connect the 3/16 inch (4.8 mm) I.D. gas
hose from the gun to the barbed fitting.

When you need to remove the gun, you can easily
detach this fitting by loosening the union nut.

INSTALLATION

A-14 A-14

LN-9 GMA Wire Feeder

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WARNING

FIGURE A.10 – SHIELDING GAS HOOKUP

TABLE OF CONTENTS

- OPERATION SECTION -

Section B-1 Section B-1

LN-9 GMA Wire Feeder

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Operation

Operating Instructions.................................................................................................................B-2

Safety Precautions......................................................................................................................B-2

General Description ....................................................................................................................B-3

Recommended Processes and Equipment.................................................................................B-3

K424 LN-9 GMA 2-Roll and K568-1 LN-9 GMA 4-Roll.........................................................B-3

K436 LN-9F GMA 2-Roll and K538-1 LN-9 GMA 4-Roll ......................................................B-3

DC Constant Voltage Power Sources..................................................................................B-4

Controls and Settings..................................................................................................................B-5

Circuit Protection and Automatic Shutdown.........................................................................B-8

Avoiding Grounding Lead Protector (GLP) Shutdown..........................................................B-8

Drive Roll Installation ................................................................................................................B-10

Changing Drive Rolls for 2-Roll Wire Feeders...................................................................B-10

Changing Drive Rolls for 4-Roll Wire Feeders...................................................................B-12

Wire Loading.............................................................................................................................B-14

Loading a 22 to 30 lb. Reddi-Reel Package.......................................................................B-14

Loading a 10 to 30 lb. Spool ..............................................................................................B-15

Loading 50 to 60 lb. Coils...................................................................................................B-16

Loading and Feeding 13-14 lbs. Innershield Coils.............................................................B-17

Idle Roll Pressure Setting .........................................................................................................B-18

2-Roll Wire Feeders............................................................................................................B-18

4-Roll Wire Feeders............................................................................................................B-18

Making a Test Weld and Adjusting Response and Starting......................................................B-19

Adjust the Power Source....................................................................................................B-19

Adjust the LN9 GMA Controls ............................................................................................B-19

Voltage Control Response..................................................................................................B-20

Starting Characteristics.......................................................................................................B-20

Making a Weld ....................................................................................................................B-21

Procedure at End of Coil...........................................................................................................B-21

Security of Weld Procedure Settings........................................................................................B-21

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B-2

B-2

LN-9 GMA Wire Feeder

OPERATING INSTRUCTIONS

Read and understand this entire section of operating
instructions operating the machine.

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such
as output terminals or internal wiring.

• Insulate yourself from the work and
ground.

• Always wear dry insulating gloves.

FUMES AND GASES can be
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to remove
fumes from breathing zone.

WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

ARC RAYS can burn.

• Wear eye, ear, and body protection.

WARNING

OPERATION

GENERAL DESCRIPTION

The LN-9 GMA 2-Roll and 4-Roll semiautomatic wire
feeder models feature the precise "set and forget" dig­ital procedure control and the other welding and oper­ator features pioneered by the original LN-9 models.
In addition, the LN-9 GMA models also have the fol­lowing advantages for small wire gas metal arc weld­ing with solid or flux cored Outershield®electrodes:

• High speed wire drive with a high torque permanent
magnet motor and tool-less "quickrelease" idle roll
pressure arms, guide tubes and gun cable fastening.

• Factory installed gas solenoid valve with gas inlet and
outlet fittings.

• Adjustable preflow, postflow and burnback timers.
Purge and cold inch switch functions are available.

• For 4-Roll models, a design which provides the addi­tional feeding force. This is required when using gun
cables over 15 ft. long or when wire is being pulled
long distances (for example, bulk packages).
Because the 4-Roll feeder has twice the contact sur­face, it can also help when feeding softer wires. It
delivers the same or more feeding force as the 2-Roll
with less overall wire deformation. Wire size range,
speed and features are the same as other LN-9 GMA
models.

RECOMMENDED PROCESSES AND
EQUIPMENT

The LN-9 GMA is available in four models:

K424 LN-9 GMA 2-ROLL AND K568-1 LN-9
GMA 4-ROLL

Wire feed unit and all controls completely enclosed in
a single portable enclosure. See Figure B-1.

K436 LN-9F GMA 2-ROLL AND K583-1
LN-9F GMA 4-ROLL

Separate wire feed unit and control box with 16 ft cable
assembly for boom or fixture mounting. See Figure
B.2.

When combined with the broad selection of quality
welding equipment and accessories, the LN-9 GMA
provides a versatile precision welding system to meet
the specific needs of gas metal arc and Innershield®or
submerged arc welding processes. The capabilities of
the LN-9 GMA 2-Roll and 4-Roll are:

Rated wire size range:

.023 through 1/16 solid wire electrode.
.045 through 5/64 Outershield®cored electrode.
.062 through 5/64 lnnershield®cored electrode.

Rated wire speed range:

80 through 980 inches per minute.
(2.03 through 24.9 meters per minute).

OPERATION

B-3 B-3

LN-9 GMA Wire Feeder

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FIGURE B.1 – BASIC LN-9 GMA HOOKUP

FIGURE B.2 – BASIC LN-9F GMA HOOKUP

K196-XXX,

DC CONSTANT VOLTAGE POWER
SOURCES

The following welding system power sources are avail­able for use with all LN-9 GMA models:

The Idealarc®DC-250, DC-400, CV-400, CV-500 and,
DC-600 are recommended for use with any LN-9 GMA
model, as well as the Pulse Power 500, Invertec V300,
and DC650 Pro, with the installation of the optional
K442-1 Pulse Power Filter Kit.

OPERATION

B-4 B-4

LN-9 GMA Wire Feeder

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OPERATION

B-5 B-5

LN-9 GMA Wire Feeder

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CONTROLS AND SETTINGS

Operator controls for LN-9 GMA models are shown in
Figure B.3. Controls for LN-9F models are shown in
Figure B.4. Refer to these figures and the following
descriptions of the controls.

ELECTRODE POLARITY SWITCH: The polarity
switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 2-Roll and 4-Roll control box. Set the
switch to the same polarity as the electrode lead con­nection to the power source. If the switch is not set
for the correct polarity, the wire feeder will stop weld­ing shortly after the arc is struck. See the topic

"Automatic Shutdown"

later in this section of the

manual.
WIRE FEED DIRECTION SWITCH: The direction

switch is located inside the wire drive section on the
LN-9 GMA model and on the front panel of both the
LN-9F GMA 2-Roll and 4-Roll control box. This switch
permits the wire to be fed in either direction when the
trigger is pressed or when using the cold inch switch
feature of the K418 and K419 options. Be sure this
switch is set for forward feed when you are ready to
weld.

HOT-COLD TRIGGER INTERLOCK SWITCH: This
switch is located on the front rail on the LN-9 GMA
model and on the front panel of both the LN-9F GMA
2-Roll and 4-Roll control box. The three-position
switch serves a dual purpose:

1. "Hot-Cold" Wire Feed - In the center position the
wire will be electrically cold when feeding with the
gun trigger. In either the up or down positions the
wire will be "hot" when feeding with the gun trigger.

2. Trigger Interlock Function - In the down position
the trigger interlock will be OFF, allowing the gun
trigger to function in the normal mode. This stops
wire feed and welding when the trigger is released.
In the up position the trigger interlock will be ON.
The trigger interlock feature functions as follows:

a) When you are not welding, the trigger will function

in the normal mode, which feeds only when the
trigger is closed.

b) Once the welding arc has been struck, the gun trig-

ger may be released. Welding will continue until
one of the following occurs:

• The arc is extinguished by quickly pulling the gun

away from the work.

or

• The trigger is again depressed and released.

(This feature is not on earlier versions unless the
L7265-1 PM Power Board has been replaced
with a superceded version.)

FIGURE B.3 – WIRE FEEDER CONTROLS FOR LN-9 GMA

OPERATION

B-6 B-6

LN-9 GMA Wire Feeder

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OPERATION

B-7 B-7

LN-9 GMA Wire Feeder

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FIGURE B.4 – WIRE FEEDER CONTROLS FOR LN-9F GMA

OPERATION

B-8 B-8

LN-9 GMA Wire Feeder

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CIRCUIT BREAKER AND GROUNDING LEAD PRO­TECTOR (GLP) RESET SWITCH: These protection

circuit devices are located on the front rail of the LN-9
GMA model and bottom panel of the LN-9F models.
See the topic

"Circuit Protection and Automatic

Shutdown"

later in this section of the manual.

DIGITAL METER: A three-digit digital meter is provid­ed to set and monitor the welding procedure. The arc
voltage is displayed in volts and the wire feed speed is
displayed in inches/minute or meters/minute.

METER READING SWITCH, VOLTS AND WIRE
SPEED CONTROLS: This four-position rotary switch

is located to the right of the digital meter on LN-9 GMA
models and to the left of the digital meter on LN-9F
models. When set to the "Volts" position, the meter
reads the arc voltage setting as adjusted by the "Volts"
control. The rated setting range for all the LN-9 GMA
models is 12.0 to 60.0 volts.

The three "Wire Speed" positions include an English
position, for meter readings in inches/minute; and "LO"
and "HI" range metric positions for meter readings in
meters/minute. The wire feed speed setting is adjust­ed by the "Wire Speed" control. The rated setting
range for all the LN-9 GMA models are 80 to 980 inch­es/minute (2.03 to 24.9 meters/minute).

When using metric meter readings, set the switch to
"LO" for more precise meter readings up to 393 in/min
(9.99 m/min.). For higher wire feed speeds, the "LO"
position will result in an over-range meter reading of
E.EE which indicates that the "HI" range, with single
decimal place resolution, should be used. Similarly,
EEE will be displayed on the English position if the set­ting exceeds 999 inches/minute.

The procedure adjustments can be made before or
during the weld. This feature permits the operator to
set the welding voltage and wire speed before welding
and without assistance.

Once set, the control circuits of the LN-9 GMA will con­tinuously monitor the volts and wire speed and correct
any deviation from the set value so there will be negli­gible change.

Should the range of the power source output voltage be
such that the unit circuit cannot keep the arc voltage as
set, the unit will stop welding shortly after the arc is struck.
See the topic

"Circuit Protection and Automatic

Shutdown"

later in this section of the manual.

SET-ACTUAL PUSHBUTTON: After the weld has
been started, the ACTUAL voltage or wire speed can
be read by pressing the pushbutton to the left of the
meter. The METER READING switch must be set in
the desired position. When the pushbutton is not being
operated, the meter continues to read the SET value.

CIRCUIT PROTECTION AND AUTOMATIC
SHUTDOWN

CIRCUIT BREAKER

The circuit breaker normally trips only when excessive
loading in the wire feed cable or a defective motor or
control component causes an overload. After allowing
a minute for cooling, push in the circuit breaker button
and weld. If it trips again, be sure the wire feed cable
is clean and the proper size for the wire diameter being
fed. If the breaker still trips, look for a defective elec­trical component. When the circuit breaker is tripped,
the digital meter is off and the trigger circuit will not
operate.

POWER SUPPLY FUSE

The fuse on the PM power board inside the control box
protects the power supply circuit. When the fuse is
blown, the digital meter is off and the trigger circuit will
not operate.

VOLTAGE PC BOARD FUSE

The 1/8 amp fast-blow fuse protects the LN-9 GMA cir­cuitry from damage that may result from a ground, or
case, faulted control lead. If this fuse blows, the LN-9
GMA arc voltage sensing lead circuit will be opened.
See the topic

"Automatic Shutdown"

below.

AVOIDING GROUNDING LEAD PROTECTOR
(GLP)

SHUTDOWN

The frames of all LN-9 GMA wire feed units and drive
motors are grounded to the frame of the power source
by a lead in the control cable. An overload protector
prevents welding current from damaging this lead if the
electrode circuit touches the wire feeder frame while
the gun trigger is pressed.